Vacuum insulated door structure and method for the creation thereof

ABSTRACT

A vacuum insulated door structure includes a first wall having a first edge and a barrier layer, a second wall having a second barrier layer and a second edge coupled to the first wall member proximate the first perimetrical edge. The second wall includes at least four inner side walls and a back wall that defines a second wall offset. At least one tubular member extends between the first wall member and the second wall offset, wherein an inner conduit surface of the tubular member provides fluid communication between the first wall outer facing surface and the second wall outer facing surface. A cavity insulation material is disposed within a cavity volume defined between the first and second walls, wherein the cavity volume is hermetically sealed, and wherein the cavity volume includes an at least partial vacuum.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 14/635,109 filed Mar. 2, 2015, entitled VACUUM INSULATED DOORSTRUCTURE AND METHOD FOR THE CREATION THEREOF, which is a continuationof U.S. patent application Ser. No. 13/833,696 filed Mar. 15, 2013,entitled VACUUM INSULATED DOOR STRUCTURE AND METHOD FOR THE CREATIONTHEREOF, which claims priority to U.S. Provisional Patent ApplicationSer. No. 61/618,914, filed on Apr. 2, 2012, entitled ENERGY EFFICIENTHOME APPLIANCES.

The present application is also related to U.S. patent application Ser.No. 13/833,635 filed Mar. 15, 2013, entitled A METHOD TO CREATE VACUUMINSULATED CABINETS FOR REFRIGERATORS; and U.S. patent application Ser.No. 13/836,669 filed Mar. 15, 2013, entitled FOLDED VACUUM INSULATEDSTRUCTURE; and U.S. patent application Ser. No. 13/835,449 filed Mar.15, 2013, entitled A VACUUM PANEL CABINET STRUCTURE FOR A REFRIGERATOR,now U.S. Pat. No. 8,944,541; and U.S. patent application Ser. No.13/832,246 filed Mar. 15, 2013, entitled DUAL COOLING SYSTEMS TOMINIMIZE OFF-CYCLE MIGRATION LOSS IN REFRIGERATORS WITH A VACUUMINSULATED STRUCTURE; and U.S. patent application Ser. No. 13/836,143filed Mar. 15, 2013, entitled VACUUM INSULATED STRUCTURE TUBULAR CABINETCONSTRUCTION; and U.S. patent application Ser. No. 13/837,659 filed Mar.15, 2013, entitled FOLDED VACUUM INSULATED STRUCTURE; and U.S. patentapplication Ser. No. 13/833,685 filed Mar. 15, 2013, entitled METHOD TOCREATE VACUUM INSULATED CABINETS FOR REFRIGERATORS, all of which areincorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The invention is in the field of vacuum insulated door panels andmethods for creating vacuum insulated door panels for use inrefrigerators.

SUMMARY

In one aspect, a vacuum insulated door structure includes a first wallmember having a first perimetrical edge, at least four outer sidewallsthat extend substantially perpendicular from the first perimetrical edgeand to a perimetrical lip, a first inner facing surface and a firstouter facing surface. A second wall member includes a second innerfacing surface, a second outer facing surface and a second perimetricaledge coupled to the first wall member proximate the perimetrical lip,wherein the second wall member comprises at least four inner side wallsdefining a second wall opening distal from at least a portion of thesecond perimetrical edge, and wherein the at least four inner sidewallsextend from the second wall opening toward the first wall member to aback wall, wherein the at least four sidewalls and the back wall definea second wall offset. At least one tubular member has first and secondconduit ends, an inner conduit surface and an outer conduit surface,wherein the first conduit end is coupled to a first wall conduit openingdefined by the first wall member and the second conduit end is coupledto a second wall conduit opening defined by the second wall offset, andwherein the inner conduit surface provides a fluid communication betweenthe first wall outer facing surface and the second wall outer facingsurface, and wherein the first and second wall members and the at leastone tubular member form a door structure. A barrier layer includes ahermetic barrier film and a heat sealing layer disposed on at least aportion of the first and second wall members and the tubular member. Acavity insulation material is disposed within a cavity volume defined byan interior volume of the door structure, wherein the cavity volume ishermetically sealed, wherein the cavity volume includes an at leastpartial vacuum.

In another aspect, a refrigerator having a vacuum insulated doorstructure comprises an insulative first wall member having a firstperimetrical edge, a first inner facing surface and a first outer facingsurface, wherein the first wall member comprises at least four offsetsidewalls defining a first wall opening distal from at least a portionthe first perimetrical edge, and wherein the at least four offsetsidewalls extend substantially orthogonally from the first wall openingto a first back wall, wherein the at least four offset sidewalls and thefirst back wall include a first wall offset. An insulative perimetricalflange has a first lip and a second lip, wherein the first lip iscoupled to the first wall member proximate the first perimetrical edge.An insulative second wall member has a second inner facing surface, asecond outer facing surface, and a second perimetrical edge coupled tothe perimetrical flange proximate the second lip, wherein the secondwall member comprises at least four inner side walls defining a secondwall opening distal from at least a portion of the second perimetricaledge, and wherein the at least four inner sidewalls extend from thesecond wall opening toward the first wall member to a second back wall,wherein the at least four inner sidewalls and the second back wallinclude a second wall offset disposed proximate the first wall opening.An insulative tubular member has first and second conduit ends, an innerconduit surface, and an outer conduit surface, wherein the first conduitend is coupled to the first wall member proximate a first wall conduitopening defined by the first wall offset and the second conduit end iscoupled to the second wall member proximate a second wall conduitopening defined by the second wall offset, and wherein the inner conduitsurface provides a fluid communication between the first wall outerfacing surface and the second wall outer facing surface, and wherein thefirst and second wall members, the perimetrical flange, and the tubularmember form a door structure. A barrier layer includes a hermeticbarrier film and a heat sealing layer disposed on at least a portion ofthe first and second wall members, the perimetrical flange, and thetubular member. A cavity insulation material is disposed within a cavityvolume defined by the inner facing surface of the first wall member, theinner facing surface of the second wall member, the perimetrical flange,and the outer conduit surface, wherein the cavity volume is hermeticallysealed and is configured to maintain an at least partial vacuum withinthe cavity volume.

In yet another aspect, a method for creating an integral vacuuminsulated door structure includes providing a first wall member having afirst perimetrical edge, at least four outer sidewalls that extendsubstantially perpendicular from the first perimetrical edge to aperimetrical lip, a first inner facing surface, and a first outer facingsurface, wherein the first wall member comprises at least four offsetsidewalls defining a first wall opening distal from at least a portionthe first perimetrical edge, and wherein the at least four offsetsidewalls extend substantially orthogonally from the first wall openingto a first back wall, wherein the at least four offset sidewalls and thefirst back wall include a first wall offset. A second wall memberincludes a second inner facing surface, a second outer facing surface,and a second perimetrical edge disposed proximate the perimetrical lip,wherein the second wall member comprises at least four inner sidewallsdefining a second wall opening distal from at least a portion of thesecond perimetrical edge, and wherein the at least four inner sidewallsextend from the second wall opening toward the first wall member to aback wall, wherein the at least four sidewalls and the back wall definea second wall offset. A tubular member includes first and second conduitends, an inner conduit surface and an outer conduit surface, wherein thefirst conduit end is disposed to a first wall conduit opening defined bythe first wall member and the second conduit end is disposed to a secondwall conduit opening defined by the second wall offset, and wherein theinner conduit surface provides a fluid communication between the firstwall outer facing surface and the second wall outer facing surface. Abarrier layer comprises a hermetic barrier film and a heat sealing layeron at least a portion of the first and second wall members, and thetubular member. A cavity insulation material is disposed within a cavityvolume defined by the inner facing surface of the first wall member, theinner facing surface of the second wall member, and the outer conduitsurface. The cavity volume is hermetically sealed. Gas is extracted fromthe cavity volume via at least one port disposed on the first wallmember proximate a port opening defined by the first wall member,wherein the cavity volume is configured to maintain an at least partialvacuum within the cavity volume.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a top perspective of a refrigerator containing one embodimentof the vacuum insulated door structure with the door in the openposition;

FIG. 2 is a top perspective view of the refrigerator of FIG. 1 with thedoor in the closed position;

FIG. 3 is a bottom exploded perspective view of one embodiment of thevacuum insulated door structure;

FIG. 4 is a top perspective of the vacuum insulated door structure ofFIG. 3;

FIG. 5 is a cross-sectional view of the vacuum insulated door structureof FIG. 4 taken at line V-V;

FIG. 6 is a front elevational view of the vacuum insulated doorstructure of FIG. 3;

FIG. 7 is a rear elevational view of the vacuum insulated door structureof FIG. 3;

FIG. 8 is a side elevational view of the vacuum insulated door structureof FIG. 3;

FIG. 9 is a top plan view of the vacuum insulated door structure of FIG.3;

FIG. 10 is a bottom plan view of the vacuum insulated door structure ofFIG. 3;

FIG. 11 is an exploded cross-sectional view of the vacuum insulated doorstructure of FIG. 5;

FIG. 12 is a cross-sectional view of one embodiment of the vacuuminsulated door structure;

FIG. 13 is a partially exploded top perspective view of the refrigeratorof FIG. 1; and

FIG. 14 is a schematic flow diagram showing a method for creating thevacuum insulated door structure of FIG. 1.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

With respect to FIG. 1, a refrigerator 10 is generally shown. In each ofthese embodiments, the refrigerator 10 can have at least one door 12operable between open and closed positions, and an interior 14 whereinthe door 12 selectively provides access to the interior 14 of therefrigerator 10 when the door 12 is in the open position. As will bemore fully described below, the refrigerator 10 can also include acooling loop having an evaporator, a condenser, and/or coolant fluidthat can be configured to provide cooling to at least a portion of thedoor 12.

A first aspect, as illustrated in FIGS. 1-5, includes a vacuum insulateddoor structure 30 that can be disposed within the at least one door 12of the refrigerator 10. The vacuum insulated door structure 30 includesa first wall member 32 having a first perimetrical edge 34 and at leastfour outer side walls 36 that extend substantially perpendicular fromthe first perimetrical edge 34 to a perimetrical lip 38. The first wallmember 32 also includes a first inner facing surface 40 and a firstouter facing surface 42.

As shown in FIG. 3, the vacuum insulated door structure 30 also includesa second wall member 50 having a second inner facing surface 52 and asecond outer facing surface 54, and a second perimetrical edge 56. Thesecond perimetrical edge 56 is coupled to the first wall member 32proximate the perimetrical lip 38. At least four inner sidewalls 58 areincluded in the second wall member 50 and define a second wall opening60 configured to be distal from at least a portion of the secondperimetrical edge 56. The at least four inner sidewalls 58 extend fromthe second wall opening 60 toward the first wall member 32 to a backwall 62. The at least four inner sidewalls 58 and the back wall 62define a second wall offset 64.

As shown in FIGS. 3-5, the vacuum insulated door structure 30 caninclude at least one tubular member 80 that includes first and secondconduit ends 82, 84, an inner conduit surface 86 and an outer conduitsurface 88. The first conduit end 82 is coupled to a first wall conduitopening 90 defined by the first wall member 32 and the second conduitend 84 is coupled to a second wall conduit opening 92 defined by thesecond wall offset 64. In this manner, the inner conduit surface 86provides a fluid communication between the first outer facing surface 42and the second outer facing surface 54.

The first and second wall members 32, 50 and the at least one tubularmember 80 form the vacuum insulated door structure 30 that includes anoutside surface 100 and an inside surface 102, wherein the insidesurface 102 defines a cavity volume 104 that is hermetically sealed. Abarrier layer 106 comprising a hermetic barrier film and a heat sealinglayer are disposed on at least a portion of the first and second wallmembers 32, 50 and the tubular member 80. A cavity insulation material108 is also disposed within the cavity volume 104 and the cavity volume104 is configured to maintain at least partial vacuum within the cavityvolume 65.

According to one embodiment, the first and second wall members 32, 50and the at least one tubular member 80 can be made of materials thatinclude, but are not limited to, high impact polystyrene oracrylonitrile butadiene styrene that has been thermally formed into theshape described above. While not preferred, it is understood that thefirst and second wall members 32, 50 and the at least one tubular member80 can also be formed by attaching various members together to form thevacuum insulated door structure 30, as described above.

Referring to the illustrated embodiment, as illustrated in FIGS. 3 and5, the first wall member 32 can include at least four offset sidewalls120 that define a first wall opening 122 configured to be distal from atleast a portion of the first perimetrical edge 34, and wherein the atleast four offset sidewalls 120 extend substantially orthogonally fromthe first wall opening 122 to an offset back wall 124, such that theoffset inner sidewalls 120 and the offset back wall 124 includes a firstwall offset 126. In this embodiment, the offset back wall 124 of thefirst offset is disposed proximate the back wall 62 of the second walloffset 64. In addition, the at least one tubular member 80 is coupled tothe first wall member 32 proximate the first wall conduit opening 90defined by the first wall offset 126, and extends to the second conduitend 84 which is coupled to the second wall member 50 proximate thesecond wall conduit opening 92, defined by the second wall offset 64.

Referring now to FIGS. 3-5 of the illustrated embodiment, the barrierlayer 106 disposed on the first and second wall members 32, 50 and theat least one tubular member 80 can include at least one layer ofpolymeric barrier films and at least one heat sealing layer. The one ormore polymeric barrier films can include, but are not limited to,ethylene vinyl alcohol co-polymer, or polyvinylidene chloride films. Thebarrier layer 106 can be disposed upon the first and second wall members32, 50 and the at least one tubular member 80 by thermally forming thebarrier layer 106 onto the first and second wall members 32, 50 and theat least one tubular member 80 by methods that include, but are notlimited to, laminating, co-extruding, or coating the barrier layer 106onto the first and second wall members 32, 50 and the at least onetubular member 80. Alternatively, these and other methods can be used todispose the barrier layer 106 onto panels that will be formed into thefirst and second wall members 32, 50 and the at least one tubular member80.

In various embodiments, the barrier layer 106 provides a hermeticsurface to the first and second wall members 32, 50 and the at least onetubular member 80 to increase the ability of the vacuum insulated doorstructure 30 to retain a vacuum within the cavity volume 104. Thebarrier layer 106 can be disposed on the first inner facing surface 40of the first wall member 32, the second inner facing surface 52 of thesecond wall member 50, and the outer conduit surface 88 of the at leastone tubular member 80, whereby the barrier layer 106 is disposedproximate the cavity volume 104 and substantially seals the cavityvolume 104. In this manner, the barrier layer 106, being within thecavity volume 104, is substantially protected from damage that can becaused by handling and installation of the vacuum insulated doorstructure 30 within the refrigerator 10. In less preferred embodiments,the barrier layer 106 can be disposed on the first outer facing surface42 of the first wall member 32, the second outer facing surface 54 ofthe second wall member 50, and the inner conduit surface 86 of the atleast one tubular member 80.

In other alternate embodiments, the vacuum insulated door structure 30can be formed by disposing a perimetrical flange having a first lip anda second lip to the first wall member 32 and the second wall member 50,such that the first lip is coupled to the first wall member 32 proximatethe first perimetrical edge 34 and the second lip is coupled to thesecond wall member 50 proximate the second perimetrical edge 56. In thisembodiment, the at least four outer sidewalls 36 make up theperimetrical flange.

As illustrated in FIG. 5, the cavity insulation material 108 disposedwithin the cavity volume 104 can be a low thermal conductivity materialor polyurethane foam that is disposed into the cavity volume 104. Aswill be discussed more fully below, the cavity insulation material 108can be disposed within the cavity volume 104 either before or after thefirst wall member 32 is hermetically sealed to the second wall member50. In addition, the cavity insulation material 108 can be an injectableor loose material that can be injected into the cavity volume 104through at least one port 150. In alternate embodiments, the cavityinsulation material 108 can be a preformed substantially rigid material,where the preformed shape of the cavity insulation material 108typically and substantially matches the shape of the cavity volume 104.In such an embodiment, the preformed cavity insulation material 108 isconfigured to be received by the first inner facing surface 40 of thefirst wall member 32, and is further configured to receive the secondinner facing surface 52 of the second wall member 50. The preformedcavity insulation material 108 can also be configured to receive the atleast one tubular member 80 and the first and second wall offsets 126,64. In this manner, the preformed cavity insulation material 108substantially fills the cavity volume 104 without having to inject thecavity insulation material 108. In addition, the preformed cavityinsulation material 108 can allow the manufacturer to inspect thequality of the cavity insulation material 108 before installation tosubstantially insure that the cavity insulation material 108 is disposedsubstantially throughout the cavity volume 104.

Referring again to the embodiment illustrated in FIGS. 3-10, and asdiscussed above, the first wall member 32, the second wall member 50,and the at least one tubular member 80 are hermetically sealed togetherto form the vacuum insulated door structure 30 and the cavity volume 104defined therein. It should be understood that the method for sealing thecavity volume 104 can vary. The methods used in the various embodimentsare sufficient to hermetically seal the cavity volume 104 in order tomaintain the desired vacuum within the cavity volume 104 of the vacuuminsulated door structure 30. These sealing methods can include, but arenot limited to, heat sealing or ultrasonic welding. The combination ofthe polymeric barrier films and the at least one heat sealing layer inconjunction with the method of sealing the cavity volume 104 creates anat least partial vacuum within the core cavity volume 104 that can bemaintained for extended periods of time, such as, at least five, ten, orfifteen years.

Referring now to the illustrated embodiment as illustrated in FIGS.4-11, the at least one port 150 can be disposed to the first outerfacing surface 42 of the first wall member 32. The at least one port 150can include an extruded tube 160 that can be attached to a port opening162 defined by a portion of the first or second wall members 32, 50. Theport 150 provides a fluid communication between the outside of thevacuum insulated door structure 30 and the cavity volume 104, so thatmaterial can be passed from within the cavity volume 104 to the outsideof the vacuum insulated door structure 30, or vice versa.

As illustrated in FIG. 5, after the cavity volume 104 is sealedtogether, the port 150 can be used as a vacuum port 164 to draw out gas166 that may be present in the cavity volume 104 with the cavityinsulation material 108. Once the desired amount of gas 166 is extractedfrom the cavity volume 104, the port 150 can be removed, and the portopening 162 in the first or second wall member 32, 50 can be closed andhermetically sealed to maintain the desired vacuum within the cavityvolume 104. It should be understood that in various embodiments, morethan one port 150 can be used to extract gas 166 from the cavity volume104.

Referring again to the illustrated embodiment as shown in FIGS. 3, 5 and11, the cavity insulation material 108 can be disposed within the cavityvolume 104 either before or after the first wall member 32 ishermetically sealed to the second wall member 50. Where the cavityinsulation material 108 is disposed within the cavity volume 104 afterthe cavity volume 104 is hermetically sealed, at least one injectionport 168 can be disposed to the outside surface 100 of the vacuuminsulated door structure 30 at the one or more port openings 162 definedtherein so that there can be a fluid communication between the outsidesurface 100 of the vacuum insulated door structure 30 and the cavityvolume 104. The cavity insulation material 108 can then be injectedthrough the at least one injection port 168 into the cavity volume 104.The at least one vacuum port 164 can also be disposed on the outsidesurface 100 of the vacuum insulated door structure 30 as described aboveto extract the desired amount of gas 166 from the cavity volume 104, andto aid in the injection of the cavity insulation material 108 throughoutthe cavity volume 104. Once the desired amount of cavity insulationmaterial 108 is injected into the cavity volume 104, and the desiredamount of gas 166 is extracted from the cavity volume 104, the injectionport 168 and the vacuum port 164 can be removed, and the port openings162 closed and hermetically sealed to maintain the desired vacuum withinthe cavity volume 104.

It should be appreciated that a perfect vacuum is not necessary withinthe hermetically sealed cavity volume 104. Various levels of gas 166 canremain within the cavity volume 104 without degrading the efficiency oreffectiveness of the vacuum insulated door structure 30.

Referring now to the embodiment illustrated in FIG. 12, the vacuuminsulated door structure 30 can be configured to include a modulereceptacle 190 disposed proximate the first wall offset 126 and thefirst wall conduit opening 90, such that the module receptacle 190 is incommunication with the inner conduit surface 86. The module receptacle190 is also in communication with the cooling loop, wherein the modulereceptacle 190 is configured to receive at least one cooling module 192that can be coupled with the cooling loop of the refrigerator 10.

In various embodiments, more than one module receptacle 190 can bedefined by the vacuum insulated door structure 30 such that more thanone cooling module 192 can be disposed on the vacuum insulated doorstructure 30 and connected to one or more cooling loops of therefrigerator 10. The location of the module receptacles 190 on thevacuum insulated door structure 30 can define the location of variousspecialty cooling modules 192 that can be placed upon and typicallyremovably mounted to one or more module receptacles 190 (by hand andwithout the use of tools) of the refrigerator 10. By way of explanation,and not limitation, examples of cooling modules 192 can include at leastone of a turbo chill module;

-   -   a fast freeze module;    -   a shock freeze module;    -   a temperature controlled crisper compartment module;    -   a fresh food compartment module;    -   an ice making module;    -   a heat exchanger module for dispensing cold or chilled water;    -   a heat exchanger module for creating cold or chilled water to        facilitate its carbonation and dispense a carbonated beverage;        and    -   an airless cooling module.

In addition, the cooling modules 192 having at least one productdispensing function can be placed in the module receptacle 190 proximatethe first wall offset 126, such that the cooling module 192 is in fluidcommunication with the inner conduit surface 86, the second outer facingsurface 54, and the second wall offset 64. In this manner, cooledproducts from the cooling modules 192 having at least one productdispensing function can be disposed from the cooling module 192 throughthe tubular member 80 and into the second wall offset 64, such that auser of the refrigerator 10 can collect the cooled product as desired.In addition, more than one cooling module 192 can use the same tubularmember 80 as a common conduit for dispensing cooled products into thesecond wall offset 64. Alternatively, two or more tubular members 80 canbe implemented to serve two or more corresponding cooling modules 192 todispense cooled products into the second wall offset 64.

As illustrated in the embodiment of FIG. 12, an ice making module 200 isdisposed in the cooling module receptacle 190 proximate the first walloffset 126. The ice making module 200 includes an ice container 202 forcollecting ice that is made within the ice making module 200 and animpeller 204 for directing the ice collected within the ice container202 into and through the at least one tubular member 80 and to thesecond wall offset 64. A receptacle insulation material 206 can bedisposed within the module receptacle 190 and around the ice makingmodule 200 to insulate the ice making module 200, such that the use ofcooling within the cooling module 192 can be substantially maximized.The receptacle insulation material 206 can include, but is not limitedto, polyurethane foam, rigid insulation, or other insulation material.

Referring now to the embodiments of FIGS. 1, 2 and 13, the door 12 of arefrigerator 10 can include a metal clad covering 220 having a finishedouter surface 222 and an interior surface 224. The metal clad covering220 also includes a door opening 230 defined by the metal clad covering220 through which the second wall offset 64 can be accessed. Theinterior surface 224 of the metal clad covering 220 is configured to bedisposed on at least a portion of the outside surface 100 of the vacuuminsulated door structure 30. The finished outer surface 222 of the metalclad covering 220 can have varying finishes that can include, but arenot limited to, painted metal, stainless steel, magnetic stainlesssteel-type finishes, or other metallic finish. The interior surface 224of the metal clad covering 220 defines a door structure receptacle 226for receiving the outside surface 100 of the vacuum insulated doorstructure 30. In various other alternate embodiments, the outer surfaceof the vacuum insulated door structure 30 can include a finished outersurface 222 of the door of the refrigerator 10. In such an embodiment,various indicia, patterns, or colors, can be disposed on the outsidesurface 100 of the vacuum insulated door structure 30.

In other various embodiments, the outside surface 100 of the vacuuminsulated door structure 30 can include one or more integrated shelvesor one or more integrated shelf receptacles for receiving one or moreselectively removable shelves for holding items that can be cooledwithin the interior 14 of the refrigerator 10. In various otherembodiments of the refrigerator 10, the cooling loop of the refrigerator10 can be routed through a hinged portion 228 of the refrigerator 10. Inthis manner, the main loop can be configured to run through the hingedportion and into the door 12 to the cooling module receptacle 190 of thevacuum insulated door structure 30. In still other various embodiments,a conduit for running the cooling loop through the vacuum insulated doorstructure 30 can be provided through the vacuum insulated door structure30 or in a space provided between the metal clad covering 220 and thevacuum insulated door structure 30, or both.

Another aspect of the refrigerator 10 as illustrated in FIG. 14 includesa method 250 for creating a vacuum insulated door structure 30 for arefrigerator 10. A first step 252 in this method 250 includes providingfirst and second wall members 32, 50 and at least one tubular member 80as described above. This step 252 of the method 250 also includesdisposing a barrier layer 106 comprising a hermetic barrier film and aheat simulator onto at least a portion of the first and second wallmembers 32, 50 and the tubular member 80. The next step 254 in themethod 250 includes hermetically sealing the first and second wallmembers 32, 50 and the at least one tubular member 80 together to createand define the cavity volume 104.

As illustrated in the embodiment of FIG. 14, the method 250 alsoincludes the step 256 of disposing a cavity insulation material 108within the cavity volume 104 defined by the first wall inner facingsurface 40, the second wall inner facing surface 52, and the outerconduit surface 88 of the at least one tubular member 80.

After the cavity insulation material 108 is disposed within the cavityvolume 104, and the cavity volume 104 is hermetically sealed, a nextstep 258 in the method 250 includes extracting gas 166 from the cavityvolume 104 through the at least one port 150 disposed on the vacuuminsulated door structure 30, wherein the cavity volume 104 is configuredto maintain at least partial vacuum within the cavity volume 104.

In the various embodiments, the cavity insulation material 108 can bedisposed within the cavity volume 104 either before or after the firstwall member 32 is hermetically sealed to the second wall member 50. Inaddition, and as described above, where the cavity insulation material108 is disposed within the cavity volume 104 after the cavity volume 104is hermetically sealed, the method 250 can include the step 256 ofinjecting the cavity insulation material 108 into the cavity volume 104through the at least one injection port 168 and into the cavity volume104. The at least one vacuum port 164 is also used to extract gas 166from the cavity volume 104 to create the desired vacuum within thecavity volume 104.

As illustrated in FIG. 14, the method 250 can also include the step 260of providing a cooling module 192 and disposing the cooling module 192within the module receptacle 190 defined by the first wall member 32proximate the first wall offset 126 and in communication with the innerconduit surface 86 and the second wall offset 64. As discussed above,when the cooling module 192 is disposed within the module receptacle190, the cooling loop is in fluid communication with the cooling module192 wherein the cooling loop includes the evaporator, condenser andcooling fluid. This step 260 of the method 250 can also includedisposing the receptacle insulation material 206 within at least aportion of the module receptacle 190 to surround and insulate thecooling module 192. As illustrated in the embodiment of FIG. 12, thecooling module 192 can include an ice maker and dispenser and a waterdispenser, wherein the ice and water dispensers are in fluidcommunication with the inner conduit surface 86 and the second walloffset 64, such that a user of the refrigerator 10 can collect cooledproducts disposed by the ice and water dispensers.

As illustrated in FIG. 14, the method 250 can also include the step 262of providing a metal clad covering 220 disposing the vacuum insulateddoor structure 30 within the door structure receptacle 226 of the metalclad covering 220, such that the interior surface 224 of the metal cladcovering 220 is proximate the outside surface 100 of the vacuuminsulated door structure 30.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine 7 ofEquivalents.

What is claimed is:
 1. A method for creating an integral vacuuminsulated door structure comprising steps of: providing a first wallmember having a first perimetrical edge, a barrier layer, a first innerfacing surface, and a first outer facing surface, wherein the first wallmember includes an offset sidewall defining a first wall opening distalfrom at least a portion of the first perimetrical edge, and wherein theoffset sidewall extends from the first wall opening to a first backwall, wherein the offset sidewall and the first back wall include afirst wall offset; providing a second wall member having a second innerfacing surface, a second outer facing surface, and a second perimetricaledge disposed proximate the first perimetrical edge, wherein the secondwall member comprises an inner sidewall defining a second wall openingdistal from at least a portion of the second perimetrical edge, a secondbarrier layer, and wherein the inner sidewall extends from the secondwall opening toward a second back wall, wherein the inner sidewall andthe second back wall define a second wall offset; providing a tubularmember having an inner conduit surface and an outer conduit surface, thetubular member extending between the first wall offset and the secondwall offset, and wherein the inner conduit surface provides a fluidcommunication between the first outer facing surface and the secondouter facing surface; disposing a cavity insulation material within acavity volume defined by the first inner facing surface of the firstwall member, the second inner facing surface of the second wall member,and the outer conduit surface; sealing the cavity volume; and extractinggas from the cavity volume via at least one port disposed on the firstwall member proximate a port opening defined by the first wall member,wherein the cavity volume is configured to maintain an at least partialvacuum within the cavity volume.
 2. The method of claim 1, wherein thevacuum insulated door structure includes a module receptacle at leastpartially defined by the first wall offset and in communication with theinner conduit surface, wherein the module receptacle is configured toreceive a cooling module, and wherein the barrier layer and the secondbarrier layer each include at least one of a barrier film and a heatsealing layer.
 3. The method of claim 1, further comprising the stepsof: providing a metal clad covering having an interior surface; anddisposing the metal clad covering to at least a portion of an exteriorof the vacuum insulated door structure such that the interior surface ofthe metal clad covering is proximate the vacuum insulated doorstructure.
 4. The method of claim 1, wherein the step of disposing thecavity insulation material within the cavity volume includes injectingpolyurethane foam into the cavity volume via the at least one port afterthe first and second wall members and the tubular member have beensealed together, wherein the at least one port includes at least oneinjection port through which the polyurethane foam is injected, andwherein the at least one port includes at least one vacuum port throughwhich the gas is extracted from the cavity volume.
 5. The method ofclaim 2, further comprising the step of: providing the cooling module;disposing the cooling module within the module receptacle, wherein thecooling module is configured to be in fluid communication with the innerconduit surface, providing a cooling loop in fluid communication withthe cooling module, wherein the cooling loop includes an evaporator anda coolant fluid; and disposing polyurethane foam within at least aportion of the module receptacle about the cooling module.
 6. The methodof claim 5, wherein the cooling module includes an ice maker anddispenser and a water dispenser, wherein the ice and water dispensersare in fluid communication with the inner conduit surface and the secondwall offset.
 7. A method for creating an integral vacuum insulated doorstructure comprising steps of: attaching a first sidewall to a secondsidewall at an outer sidewall, wherein the first sidewall has a firstwall offset and the second sidewall has a second wall offset thatsubstantially aligns with the first wall offset; attaching a tubularmember to the first and second sidewalls at the first wall offset andthe second wall offset, wherein a barrier layer is disposed on an innerfacing surface of the first sidewall, an inward facing surface of thesecond sidewall and each of the first and second sidewalls and an outerconduit surface of the tubular member; disposing a cavity insulationmaterial within a cavity volume defined by the inner facing surface ofthe first sidewall, the inward facing surface of the second sidewall,and the outer conduit surface; and sealing the cavity volume.
 8. Themethod of claim 7, further comprising a step of: extracting gas from thecavity volume via at least one port wherein the cavity volume isconfigured to maintain an at least partial vacuum within the cavityvolume to define a vacuum insulated structure.
 9. The method of claim 8,wherein the at least one port is disposed on one of the first and secondsidewalls.
 10. The method of claim 8, further comprising steps of:providing a metal clad covering having an interior surface; anddisposing the metal clad covering to at least a portion of an exteriorof the vacuum insulated door structure such that the interior surface ofthe metal clad covering is proximate the vacuum insulated structure. 11.The method of claim 7, wherein the cavity insulation material ispolyurethane foam.
 12. The method of claim 8, wherein the first walloffset includes a module receptacle that is in communication with aninner conduit surface of the tubular member.
 13. The method of claim 12,wherein the module receptacle is configured to receive a cooling module.14. The method of claim 13, further comprising steps of: providing thecooling module; disposing the cooling module within the modulereceptacle, wherein the cooling module is configured to be in fluidcommunication with the inner conduit surface, providing a cooling loopin fluid communication with the cooling module, wherein the cooling loopincludes an evaporator and a coolant fluid; and disposing polyurethanefoam within at least a portion of the module receptacle about thecooling module.
 15. A method for creating an integral vacuum insulatedstructure comprising steps of: forming a door structure having first andsecond sidewalls that are connected at an outer sidewall, a first walloffset of the first sidewall and a second wall offset of the secondsidewall that substantially aligns with the first wall offset, and atubular member that extends between the first and second sidewalls atthe first and second wall offsets, respectively; disposing a cavityinsulation material within a cavity volume defined by any inner facingsurface of the first sidewall, an inward facing surface of the secondsidewall, and an outer conduit surface of the tubular member, wherein abarrier layer is disposed on the inner facing surface of the firstsidewall, the inward facing surface of the second sidewall and the outerconduit surface of the tubular member; sealing the cavity volume; andextracting gas from the cavity volume via at least one port wherein thecavity volume is configured to maintain an at least partial vacuumwithin the cavity volume to define a vacuum insulated door structure.16. The method of claim 15, further comprising steps of: providing ametal clad covering having an interior surface; and disposing the metalclad covering to at least a portion of an exterior of the vacuuminsulated door structure such that the interior surface of the metalclad covering is proximate the vacuum insulated door structure.
 17. Themethod of claim 15, wherein the cavity insulation material ispolyurethane foam.
 18. The method of claim 15, wherein the first walloffset includes a module receptacle that is in communication with aninner conduit surface of the tubular member.
 19. The method of claim 18,wherein the module receptacle is configured to receive a cooling module,and wherein the barrier layer includes at least one of a barrier filmand a heat sealing layer.
 20. The method of claim 19, further comprisingsteps of: providing the cooling module; disposing the cooling modulewithin the module receptacle, wherein the cooling module is configuredto be in fluid communication with the inner conduit surface, providing acooling loop in fluid communication with the cooling module, wherein thecooling loop includes an evaporator and a coolant fluid; and disposingpolyurethane foam within at least a portion of the module receptacleabout the cooling module.